Energy storage device

ABSTRACT

An energy storage device includes an electrode unit in which a cathode having a cathode lead, an anode having an anode lead, and a separator located between the cathode and the anode to separate the cathode and the anode from each other are rolled together; a housing receiving the electrode unit; an electrolyte filled in the housing; an inner terminal arranged in the housing to face the electrode unit; and an outer terminal connected to the inner terminal. A groove is formed in a side of the inner terminal, and a side protrusion is formed on an inner wall of the housing at a location corresponding to the groove.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC 119(a) to Korean PatentApplication No. 10-2010-0011102 and No. 10-2010-0011103 filed inRepublic of Korea on Feb. 5, 2010, the entire contents of which areincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an energy storage device, and moreparticularly to an energy storage device that maximizes the utilizationof the inside of a housing by the improvement of an inner structurethereof and also ensures the reliability by keeping an inner pressurebelow a certain level.

2. Description of the Related Art

Generally, representative examples of a device storing an electricenergy are batteries and capacitors. Among them, a capacitor is anenergy storage device, which is called a ultra capacitor or a supercapacitor and has features in between an electrolytic condenser and asecondary battery.

Such an energy storage device makes side reactions at an interfacebetween an electrolyte and an electrode when being misused with anovervoltage or the like or used for a long time at high temperature, andgas is generated as a byproduct accordingly.

Considering the generation of gas, a conventional energy storage deviceis designed to have some space between an electrode unit and an innerside of the housing of the energy storage device.

However, in a case where the energy storage device is used for atransportation means such as a vehicle, the electrode unit in thehousing may be shaken right and left due to an external force such asvibration, and accordingly the electrode unit or a lead wire connectedthereto may be broken, which results in the deterioration of life orreliability of the energy storage device.

In addition, in a case where the inner pressure of the housing keepsincreasing due to the generation of gas, the housing may swell out, orgas may be leaked at a weak region of the housing, which may causeexplosion.

In order to prevent such explosion caused by the generation of gas, anotch structure is formed in a partial region of the housing of theconventional energy storage device, so that the notch is fractured at apressure over a certain level to allow the relief of pressure.

However, in this case, the housing is kept in an opened state after thenotch of the housing is fractured, which may seriously deteriorate theperformance of the energy storage device due to the leakage ofelectrolyte or the introduction of impurities.

SUMMARY OF THE INVENTION

The present invention is designed to solve the problems of the priorart, and therefore it is an object of the present invention to providean energy storage device capable of preventing an electrode unit frombeing broken due to an external force such as vibration by improving aninner structure of the energy storage device. Also, another object ofthe present invention is to improve the reliability of the energystorage device by preventing the excessive increase of an inner pressureof the housing and intercepting the introduction of impurities into thehousing from the outside.

In order to accomplish the above object, the present invention providesan energy storage device, which includes an electrode unit in which acathode having a cathode lead, an anode having an anode lead, and aseparator located between the cathode and the anode to separate thecathode and the anode from each other are rolled together; a housingreceiving the electrode unit; an electrolyte filled in the housing; aninner terminal arranged in the housing to face the electrode unit; andan outer terminal connected to the inner terminal, wherein a groove isformed in a side of the inner terminal, and a side protrusion is formedon an inner wall of the housing at a location corresponding to thegroove.

Preferably, the electrode unit is coupled with the inner terminal bylaser welding.

Preferably, the side protrusion is formed by partially denting the sideof the housing, and the side protrusion is formed to be fit with thegroove of the inner terminal.

Preferably, the outer terminal is fixed by bending an upper portion ofthe housing.

Preferably, the energy storage device according to the present inventionfurther includes a sealing member provided to the outer terminal at alocation where the upper portion of the housing is bent and fixed.

Preferably, the energy storage device according to the present inventionfurther includes an insulation film between the housing and both of theinner and outer terminals.

Preferably, the housing has a cylindrical shape, and the inner terminaland the outer terminal are respectively constituted by a cathode or ananode at upper and lower portions of the housing.

Preferably, the energy storage device according to the present inventionfurther includes a pressure relief unit for relieving an inner pressureof the housing, wherein openings are respectively formed in the innerterminal and the outer terminal for the communication with the outside,and wherein the pressure relief unit is installed in the openings andselectively opens the openings in association with the change of theinner pressure of the housing when the inner pressure is increased overan allowable level.

Preferably, the pressure relief unit is installed in the opening of theouter terminal.

Preferably, the energy storage device according to the present inventionfurther includes a coupling member installed through the openings of theinner and outer terminals to couple the inner and outer terminals witheach other, the coupling member having a hollow therein, wherein thepressure relief unit is mounted to a head of the coupling member so thatthe hollow of the coupling member is selectively opened or closed.

Preferably, the energy storage device according to the present inventionfurther includes a fixing member for fixing the pressure relief unit tothe openings.

Preferably, the energy storage device according to the present inventionfurther includes a sealing means interposed between the pressure reliefunit and the fixing member.

Preferably, the fixing member and the coupling member may be coupled tothe openings by screwing, inserting, or inserting and laser-welding.

Preferably, the opening of the inner terminal may have a differentdiameter from the opening of the outer terminal, and the opening of theinner terminal may have a relatively smaller diameter than the openingof the outer terminal.

In another aspect of the present invention, there is also provided anenergy storage device, which includes an electrode unit in which acathode having a cathode lead, an anode having an anode lead, and aseparator located between the cathode and the anode to separate thecathode and the anode from each other are rolled together; a housingreceiving the electrode unit; an electrolyte filled in the housing; aninner terminal arranged in the housing to face the electrode unit; anouter terminal connected to the inner terminal; and a pressure reliefunit for relieving an inner pressure of the housing, wherein openingsare respectively formed in the inner and outer terminals for thecommunication with the outside, and the pressure relief unit isinstalled in the openings and selectively opens the openings inassociation with the change of the inner pressure of the housing whenthe inner pressure is increased over an allowable level.

According to the present invention, it is possible to prevent anelectrode unit from being broken due to vibration or the like byimproving an inner structure of an energy storage device. Also, it ispossible to design the housing into a slimmer shape and increase thecapacity of the energy storage device by eliminating any need to ensurea separate space between the inside of the housing and the electrodeunit. In addition, it is possible to prevent the excessive increase ofan inner pressure of the housing and also the introduction of externalimpurities into the housing. Moreover, an opening of an electrodeterminal may be used as an electrolyte injection hole, which allowssimplifying the assembling process of the energy storage device.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and aspects of the present invention will become apparentfrom the following description of embodiments with reference to theaccompanying drawing in which:

FIG. 1 is a perspective view showing an appearance of an energy storagedevice according to the present invention;

FIG. 2 is a perspective view showing exploded and assembled states ofelectrodes, a separator, and leads, which are rolled and arranged in theenergy storage device according to the present invention;

FIG. 3 is a sectional view showing an inner configuration of the energystorage device according to the present invention;

FIG. 4 is an enlarged sectional view showing the A portion of FIG. 3;and

FIG. 5 is an enlarged sectional view showing the B portion of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Hereinafter, preferred embodiments of the present invention will bedescribed in detail with reference to the accompanying drawings. Priorto the description, it should be understood that the terms used in thespecification and the appended claims should not be construed as limitedto general and dictionary meanings, but interpreted based on themeanings and concepts corresponding to technical aspects of the presentinvention on the basis of the principle that the inventor is allowed todefine terms appropriately for the best explanation. Therefore, thedescription proposed herein is just a preferable example for the purposeof illustrations only, not intended to limit the scope of the invention,so it should be understood that other equivalents and modificationscould be made thereto without departing from the spirit and scope of theinvention.

FIG. 1 is a perspective view showing an appearance of an energy storagedevice according to the present invention, FIG. 2 is a perspective viewshowing exploded and assembled states of electrodes, a separator, andleads, which are rolled and arranged in the energy storage deviceaccording to the present invention, and FIG. 3 is a sectional viewshowing an inner configuration of the energy storage device according tothe present invention.

Referring to FIGS. 1 to 3, an energy storage device according to thepresent invention includes an electrode unit 15 in which a cathode 10having a cathode lead 6, an anode 20 having an anode lead 16, and aseparator 30 located between the cathode 10 and the anode 20 toelectrically separate the cathode 10 and the anode 20 from each otherare rolled together; a housing 40 receiving the electrode unit 15; anelectrolyte filled in the housing 40; inner cathode and anode terminals51, 52 arranged in the housing 40 to face the electrode unit 15; andouter cathode and anode terminals 61, 62 connected to the inner cathodeand anode terminals 51, 52, respectively. Also, a groove 53 is formed ina side of the inner cathode terminal 51, and a side protrusion 45 isformed on an inner wall of the housing 40 at a location corresponding tothe groove 53 and fitted into the groove 53.

The energy storage device according to the present invention includesthe housing 40 made of metal material, and the cathode 10 and the anode20, which are mounted in the housing 40.

As shown in FIG. 2, the cathode 10 has a metallic current collector, andan active material layer made of porous active carbon. The cathode lead6 is connected to one side of the cathode 10.

The current collector is generally constituted with a metallic foil, andthe active material layer is formed by widely applying active carbon onboth surfaces of the metallic current collector.

The active material layer allows storing positive or negative electricenergy, and the current collector serves as a passage of charges emittedfrom or supplied to the active material layer.

Between the cathode 10 and the anode 20, which are laminatedsubsequently, the separator 30 is arranged to limit electronicconduction between the cathode 10 and the anode 20, and an electrolyteis filled in the housing 40.

Here, the porous active material layer contains micro pores similar to aspherical shape, and thus has a great surface area. Also, the porousactive material layer gives a function of active material identically tothe cathode 10 and the anode 20, and the surface of each porous activematerial layer contacts the electrolyte.

If a voltage is applied to the cathode 10 and the anode 20, cations andanions contained in the electrolyte are moved to the cathode 10 and theanode 20, respectively, and then penetrate into the micro pores of theporous active material layer.

Here, the electrode, in other words the cathode 10 or the anode 20, andthe lead may be produced separately and then connected with each other.However, it is also possible that, in a state where the currentcollector and the lead are integrally formed with a metallic foil, theactive material layer is applied to the current collector so that theelectrode and the lead are integrally formed.

In a state where the cathode 10, the anode 20, and the separator 30,which are laminated as above, are rolled into a cylindrical shape, thecathode and anode leads 6, 16 connected to the cathode 10 and the anode20 may be evenly bent, thereby forming the electrode unit 15.

At this time, in order to facilitate the easy bending of the cathode andanode leads 6, 16, the cathode and anode leads 6, 16 may be cut atregular intervals in a length direction thereof.

In addition, in order to prevent short-circuit, upper and lower portionsof the separator 30 are preferably protruded outwards over 2 mm from thecathode 10 and the anode 20, respectively, and the cathode lead 6 andthe anode lead 16 are preferably protruded outwards over 2 mm from theseparator 30, respectively.

The housing 40 may be constituted with metallic or synthetic resinmaterial, preferably aluminum or its alloy.

The housing 40 is used for receiving the cathode 10, the anode 20, theseparator 30 for electrically separating the cathode 10 and the anode 20from each other, and the cathode and anode leads 6, 16.

The inner cathode and anode terminals 51, 52 are arranged between theelectrode unit 15 and the outer cathode and anode terminals 61, 62 inorder to electrically connect the cathode and anode leads 6, 16 of theelectrode unit 15 with the outer cathode and anode terminals 61, 62.Here, the inner cathode and anode terminals 51, 52 may be fixed to theelectrode unit 15 by laser welding in order to reduce electricresistance with the electrode unit 15 and ensure secure connection.

Since the inner cathode and anode terminals 51, 52 are coupled with theelectrode unit 15 by means of the laser welding, the inner cathode andanode terminals 51, 52 and the electrode unit 15 are locally integratedin the laser welding region, thereby minimizing micro discontinuoussurfaces and further reducing the resistance against electric flow.

FIG. 4 is an enlarged sectional view showing the A portion of FIG. 3.

As shown in FIG. 4, in the energy storage device according to thepresent invention, the groove 53 is formed in the side of the innercathode terminal 51, and the side protrusion 45 is formed on the innerwall of the housing at a location corresponding to the groove 53 of theinner cathode terminal 51, in order that the electrode unit 15 and theinner cathode unit 51 are fixed to the housing 40.

The side protrusion 45 is preferably formed by denting the sidewall ofthe housing 40 by means of beading at a location corresponding to thegroove 53 formed in the side of the inner cathode terminal 51 so thatthe protruded portion of the sidewall of the housing 40 by denting is inagreement with the groove 53 in the side of the inner cathode terminal51. The side protrusion 45 allows the electrode unit 15 coupled with theinner cathode terminal 51 to be directly fixed to the housing 40,thereby minimizing the shaking of the electrode unit 15 by an externalvibration applied to the energy storage device.

Also, the outer cathode terminal 61 is structurally combined with theupper portion of the inner cathode terminal 51. The structuralcombination between the outer cathode terminal 61 and the inner cathodeterminal 50 will be described in detail later.

In addition, an insulation film 55 is provided between the housing 40and both of the inner and outer cathode terminals 51, 61 for theelectric insulation between the housing 40 and the inner and outercathode terminals 51, 61.

Further, an end portion 46 of the housing 40 is protruded over theuppermost portion of the outer cathode terminal 61 by a predeterminedlength, and the end portion of the housing 40 is bent toward the outercathode terminal 61 to fix the housing 40 to the outer cathode terminal61. Here, a sealing member 56 may be provided to the outer cathodeterminal 61 at a location where the end portion 46 of the housing 40 isbent and fixed, so as to keep the airtightness of the energy storagedevice.

FIG. 5 is an enlarged sectional view showing the B portion of FIG. 3.

As shown in FIG. 5, in the energy storage device according to thepresent invention, openings 73, 74 are formed in the inner cathodeterminal 51 and the outer cathode terminal 61, respectively, for thecommunication with the outside, and a pressure relief unit 70 isinstalled in the opening 74 of the outer cathode terminal 61 so as torelieve an increased inner pressure of the housing 40.

The pressure relief unit 70 has an elastic member (not shown) so thatthe elastic member is operated to relieve the inner pressure of thehousing 40 if a pressure applied from the opening 73 of the innercathode terminal 51 is over a predetermined level. If the inner pressureof the housing 40 is relieved below a predetermined level, the pressurerelief unit 70 returns to its original position by means of the elasticforce of the elastic member to close the housing 40.

As mentioned above, the pressure relief unit 70 plays a role of keepingthe inner pressure of the housing below a predetermined level though apressure over a predetermined level is applied to the housing 40, andalso the pressure relief unit 70 plays a role of preventing impuritiesfrom flowing into the housing 40.

A coupling member 71 is coupled to the opening 73 of the inner cathodeterminal 51 and the opening 74 of the outer cathode terminal 61. Thecoupling member 71 is installed in the opening 73 of the inner cathodeterminal 51 and the opening 74 of the outer cathode terminal 61 andfixes the inner and outer cathode terminals 51, 61 to each other. Thecoupling member 71 also has a hollow therein. In this connection, theinner cathode terminal 51 and the outer cathode terminal 61 arestructurally secured, and also the openings 73, 74 may be used as anelectrolyte injection hole, which allows simplifying the assemblingprocess of the energy storage device.

Here, the opening 73 of the inner cathode terminal 51 preferably has arelatively smaller diameter than the opening 74 of the outer cathodeterminal 61. In this case, a step is formed between the openings 73, 74due to the difference in diameters, and thus the coupling member 71 maybe secured in a more stable way.

In addition, the coupling member 71 may have the same thickness at aregion located at the opening 73 of the inner cathode terminal 51 and aregion located at the opening 74 of the outer cathode terminal 61 sothat the step formed due to the difference in diameters of the openings73, 74 is also formed in the coupling member 71. This step may be usedas a support when the pressure relief unit 70 is installed.

Here, the coupling member 71 may be constituted as a bolt on which athread is formed, and a thread corresponding thereto may be formed inthe opening 73 of the inner cathode terminal 51 and the opening 74 ofthe outer cathode terminal 61 so that the coupling member 71 is fixed tothe inner and outer cathode terminals 51, 61 by means of bolt coupling.

As described above, in a state where the coupling member 71 is fixed tothe opening 73 of the inner cathode terminal 51 and the opening 74 ofthe outer cathode terminal 61, the pressure relief unit 70 is placed andinstalled in the coupling member 71. Also, in a state where the couplingmember 71 is installed, a fixing member 72 is coupled to the opening 74of the outer cathode terminal 61 in order to fix the pressure reliefunit 70.

Here, the fixing member 72 may be constituted as a bolt on which athread is formed, and a thread corresponding thereto may be formed inthe opening 74 of the outer cathode terminal 61 so that the fixingmember 72 fixes the pressure relief unit 70 by means of bolt coupling.In addition, a sealing means (not shown) such as an O-ring may befurther interposed between the pressure relief unit 70 and the fixingmember 72 in order to prevent the electrolyte from leaking out. Also,the fixing member 72 may be inserted into the opening 74 of the outercathode terminal 61, or for the better coupling, the pressure reliefunit 70 may be fixed thereto by means of laser welding after the fixingmember 72 is inserted into the opening 74 of the outer cathode terminal61.

Meanwhile, though it is illustrated in this embodiment that the pressurerelief unit 70 is installed to the opening 73 of the inner cathodeterminal 51 and the opening 74 of the outer cathode terminal 61, thepresent invention is not limited thereto, and it is obvious that thepressure relief unit 70 may also be installed on the inner anodeterminal 52 and the outer anode terminal 62. In this case, when theinner pressure of the housing 40 is increased, the increased pressuremay be relieved at both upper and lower portions of the housing 40,which may solve any problem caused by the directivity of pressure.

As described above, the energy storage device according to the presentinvention allows the inner pressure of the housing 40 to beautomatically relieved when the inner pressure exceeds a predeterminedlevel, and thus there is no need to form a separate space between theelectrode unit 15 and the inner side of the housing 40 where theelectrode unit 15 is located, which was required conventionally inconsideration of the generation of gas due to side reactions between theelectrode unit and the electrolyte.

In a conventional energy storage device, a space should be formedbetween the electrode unit and the inner side of the housing inconsideration of the generation of gas caused by side reactions.

However, in the present invention, since there is no need to form aseparate space between the electrode unit 15 and the inner side of thehousing 40, it is possible that the housing 40 is designed to have thesubstantially same diameter as the electrode unit 15.

Thus, the housing 40 of the energy storage device according to thepresent invention may be designed into a slimmer shape in comparison toconventional housings.

In addition, since the side protrusion 45 is fit with the groove 53 ofthe inner cathode terminal 51, the electrode unit 15 may be directlyfixed to the housing 40, and thus it is possible to minimize the shakingof the electrode unit 15 due to external vibrations applied to theenergy storage device.

Thus, it is possible to prevent the electrode unit 15 from beingdeformed or broken due to external vibrations.

Hereinafter, the present invention will be described in more detailbased on examples of the present invention and comparative examples, forbetter understanding of the present invention.

EXAMPLES AND COMPARATIVE EXAMPLES

TABLE 1 Vibration applied No vibration applied Example 12 mA 9 mAComparative 24 mA 9 mA example

The table 1 shows measurement results of leakage currents of energystorage devices (according to the example) in which the side protrusion45 is formed and fitted into the groove 53 formed in the side of theinner cathode terminal 51 according to the present invention, and energystorage devices (according to the comparative example) in which no sideprotrusion is formed, after charging for 12 hours.

As understood from the experiment results, the energy storage devicesaccording to the example and the comparative examples exhibited the sameleakage current when vibration was not applied thereto. However, whenvibration was applied, the energy storage devices according to theexample and the comparative examples exhibited different leakagecurrents.

In other words, it could be found that the energy storage deviceaccording to the example in which the side protrusion 45 is formed andfit into the groove 53 in the side of the inner cathode terminal 51exhibited a reduced leakage current by half in comparison to the energystorage device of the comparative example.

The present invention has been described in detail. However, it shouldbe understood that the detailed description and specific examples, whileindicating preferred embodiments of the invention, are given by way ofillustration only, since various changes and modifications within thespirit and scope of the invention will become apparent to those skilledin the art from this detailed description.

Reference Symbols  6: cathode lead 16: anode lead 10: cathode 15:electrode unit 20: anode 30: separator 40: housing 51: inner cathodeterminal 52: inner anode terminal 61: outer cathode terminal 62: outeranode terminal 70: pressure relief unit

1. An energy storage device, comprising: an electrode unit in which acathode having a cathode lead, an anode having an anode lead, and aseparator located between the cathode and the anode to separate thecathode and the anode from each other are rolled together; a housingreceiving the electrode unit; an electrolyte filled in the housing; aninner terminal arranged in the housing to face the electrode unit; andan outer terminal connected to the inner terminal, wherein a groove isformed in a side of the inner terminal, and a side protrusion is formedon an inner wall of the housing at a location corresponding to thegroove.
 2. The energy storage device according to claim 1, wherein theelectrode unit is coupled with the inner terminal by laser welding. 3.The energy storage device according to claim 1, wherein the sideprotrusion is formed by partially denting the side of the housing. 4.The energy storage device according to claim 1, wherein the sideprotrusion is formed to be fit with the groove of the inner terminal. 5.The energy storage device according to claim 1, wherein the outerterminal is fixed by bending an upper portion of the housing.
 6. Theenergy storage device according to claim 5, further comprising a sealingmember provided to the outer terminal at a location where the upperportion of the housing is bent and fixed.
 7. The energy storage deviceaccording to claim 1, further comprising an insulation film between thehousing and both of the inner and outer terminals.
 8. The energy storagedevice according to claim 1, wherein the housing has a cylindricalshape, and wherein the inner terminal and the outer terminal arerespectively constituted by a cathode or an anode at upper and lowerportions of the housing.
 9. The energy storage device according to claim1, further comprising a pressure relief unit for relieving an innerpressure of the housing, wherein openings are respectively formed in theinner terminal and the outer terminal for the communication with theoutside, and wherein the pressure relief unit is installed in theopenings and selectively opens the openings in association with thechange of the inner pressure of the housing when the inner pressure isincreased over an allowable level.
 10. The energy storage deviceaccording to claim 9, wherein the pressure relief unit is installed inthe opening of the outer terminal.
 11. The energy storage deviceaccording to claim 10, further comprising a coupling member installedthrough the openings of the inner and outer terminals to couple theinner and outer terminals with each other, the coupling member having ahollow therein, wherein the pressure relief unit is mounted to a head ofthe coupling member so that the hollow of the coupling member isselectively opened or closed.
 12. The energy storage device according toclaim 11, further comprising a fixing member for fixing the pressurerelief unit to the openings.
 13. The energy storage device according toclaim 12, further comprising a sealing means interposed between thepressure relief unit and the fixing member.
 14. The energy storagedevice according to claim 13, wherein the fixing member and the couplingmember are coupled to the openings by screwing, inserting, or insertingand laser-welding.
 15. The energy storage device according to claim 9,wherein the opening of the inner terminal has a different diameter fromthe opening of the outer terminal.
 16. The energy storage deviceaccording to claim 15, wherein the opening of the inner terminal has arelatively smaller diameter than the opening of the outer terminal. 17.An energy storage device comprising: an electrode unit in which acathode having a cathode lead, an anode having an anode lead, and aseparator located between the cathode and the anode to separate thecathode and the anode from each other are rolled together; a housingreceiving the electrode unit; an electrolyte filled in the housing; aninner terminal arranged in the housing to face the electrode unit; anouter terminal connected to the inner terminal; and a pressure reliefunit for relieving an inner pressure of the housing, wherein openingsare respectively formed in the inner and outer terminals for thecommunication with the outside, and the pressure relief unit isinstalled in the openings and selectively opens the openings inassociation with the change of the inner pressure of the housing whenthe inner pressure is increased over an allowable level.